JP4011699B2 - Embossed cosmetic material manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing an embossed decorative material that enables a transparent sheet base material used on the outermost surface of the embossed decorative material to be thinned.
[0002]
[Prior art]
Various embossed patterns are used for embossed decorative materials. Among them, the grain groove pattern of the wood grain pattern is a typical emboss pattern, and the texture and high quality are realized by realistically reproducing the wood grain conduit section of natural wood. Cosmetic materials with enhanced feeling and design are widely used. These are generally embossed irregularities in a portion corresponding to the cross section of a wood grain conduit of a natural wood board. In order to bring the appearance of the conduit groove closer to a natural one, more preferably, a concave portion formed by embossing is filled with a coloring material (ink or the like) having a concentration by a technique such as wiping.
Generally, the plate depth (which may be called the height of the convex portion) of a conventional embossed plate used for manufacturing an embossed decorative material is 100 μm or more in order to reproduce the appearance of a natural conduit groove. Therefore, the thickness of the base material sheet used at the time of embossing needs at least 100 micrometers.
Furthermore, in recent years, so-called doubling embossing (a method of laminating a transparent topsheet base material on a colored sheet base material by thermal fusion and simultaneously embossing the transparent topsheet base material) has been frequently used. A manufacturing method has been implemented in which a transparent topsheet substrate is melt-extruded and embossed in-line using a cooling roller as an embossed plate.
[0003]
[Problems to be solved by the invention]
In this case, a thickness of 80 μm or less is desired for the transparent topsheet base material to be embossed in order to improve efficiency during extrusion molding and reduce material costs. Therefore, the plate depth of the embossed plate must be 80 μm or less. However, if the plate depth is simply lowered, there is a problem that the design effect by embossing is weakened. This tendency is particularly remarkable in the case of oak-type wood grain pipe pattern.
The present invention has been made in view of the above-mentioned problems. The thickness of the transparent topsheet substrate is reduced, and even when an embossed plate having a shallow plate depth is used, the thick transparent topsheet substrate so far is deep. It aims at providing the manufacturing method of the embossing cosmetics with the design effect equivalent to the embossing cosmetics manufactured using the embossing plate.
[0004]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, in the present invention, a digital image data creation process of a conduit pattern of a natural wood board and a conduit border pattern surrounding the conduit pattern, and the conduit border pattern on an emboss cylinder surface coated with a resist sensitizing solution are provided. The digital image data is output (exposed) with a laser beam, developed, and only the conduit border pattern portion is made a non-resist portion. Then, the first corrosion is performed, the resist is stripped, and the conduit border recess is formed. In the first photoetching step, a resist sensitizing solution is applied to the cylinder surface on which the conduit border recess is formed, and the digital image data of the conduit pattern is output by laser light in alignment with the conduit border recess (exposure). ) that developed in the said conduit pattern portion only resist portion formed in the interior of the conduit edging recess An embossing cylinder processing step comprising: a second photoetching step of performing secondary corrosion, performing resist stripping, and forming a conduit convex portion having a conduit border recess in the periphery; and a transparent top by the emboss cylinder The sheet base material is hot-pressed, or an ultraviolet ray or electron beam curable resin liquid is applied and filled on the embossed cylinder surface, and a transparent topsheet base material is laminated as necessary. An embossing step of shaping a conduit groove surrounded by a conduit fringing convex portion into the transparent substrate by releasing the ultraviolet ray or electron beam curable resin liquid from the embossed plate after curing with ultraviolet irradiation; and Consists of. Moreover, the colored sheet base material by which the grain printing was carried out in-line with the said embossing process or offline was laminated | stacked with respect to the back surface of the said transparent top sheet base material. Further, a colorant is filled in the conduit. Furthermore, a backing material corresponding to the application is bonded to the back surface of the colored sheet base material.
[0005]
DETAILED DESCRIPTION OF THE INVENTION
The embossed decorative material to be manufactured according to the present invention is a sheet or plate that has been embossed. As the material, thermoplastic resins such as polyethylene, polypropylene, olefinic thermoplastic elastomer, polyvinyl chloride, acrylic resin, polyester resin, polyurethane resin, ABS, and polystyrene are usually used. Applications include interior materials for buildings such as walls, floors, and ceilings, doors, window frames, handrails and other fittings, housings for home appliances, furniture such as bags, containers such as boxes, interior materials for vehicles, It is a ship interior material, etc., and an arbitrary material is further used as a backing if necessary.
The typical embossed pattern (embossed pattern) targeted by the embossed decorative material manufacturing method according to the present invention is a wood grain conduit groove cross-sectional pattern (hereinafter referred to as a conduit pattern) found in a wood grain pattern reproducing a natural wood board. Therefore, the case of the conduit pattern will be described below. Needless to say, the present invention can be applied to a joint groove other than a conduit pattern, a joint groove of a tile or brick arrangement, a recessed portion of a travertine marble, a groove-like sculpture pattern (arabesque character, etc.), and the like.
[0006]
FIG. 1 is an example of a pattern in which only a conduit pattern formed by a conduit groove is extracted from a wood grain pattern found on a natural wood board. As a method for extracting only the conduit pattern as an image in this way, various methods known in the art for photoengraving a wood grain conduit pattern may be applied. For example, there is a method in which black ink is applied to the entire surface of a natural wood board, and then a photograph is taken after wiping with a doctor blade, cloth or the like and filling only the conduit groove with ink.
The individual conduit patterns appear to be irregular, but the wood conduits are often oblong, extending in substantially the same direction by being cut diagonally. Therefore, the pattern model of the conduit pattern will be shown as an ellipse below.
[0007]
FIG. 2 is a comparative explanatory view of the visual effect exhibited by the embossed decorative material produced by the method of the present invention and the embossed decorative material according to the prior art. In FIG. It is shown in contrast with the technology (right side).
2A is a plan view of the conduit pattern, and FIG. 2B is a cross-sectional view taken along line xx ′ of FIG.
As shown in FIG. 2 (a), the conduit pattern of the embossed decorative material 10 manufactured by the method for manufacturing an embossed decorative material according to the present invention has a convex shape of the conduit rim around the periphery of the conduit portion 1 (portion corresponding to the conduit groove). Part 2 is arranged. On the other hand, such a convex portion is not formed in the conventional conduit pattern. The difference between the two is more apparent when the cross-sectional structures in FIG.
The conduit part 1 according to the invention is surrounded by a conduit fringing convex part 2 of height d. Therefore, the depth of the conduit portion 1 is substantially the same as that of the conventional case, but the thickness of the transparent sheet base material 8 formed by embossing is not limited to the physical thickness as compared with the conventional case. The height can be reduced by the height d of the convex portion 2. In addition, since the visual emphasis (enhancement) effect of the unevenness provided by the conduit fringing convex portion 2 at the periphery of the conduit portion is also exhibited, it is possible to reduce the thickness by d or more.
Therefore, according to the present invention, even if the thickness of the transparent sheet substrate 8 is reduced, there is no significant change in the depth of the conduit groove. Therefore, the visual effect, that is, the design effect brought about by the conduit groove is higher than that of the conventional case. There is no inferiority.
The inside of the conduit portion 1 is colored as necessary by wiping using a dark coloring material C as in the conventional case.
[0008]
Next, the manufacturing method of the embossing decorative material by this invention is demonstrated.
FIG. 3 is a plan view of a conduit pattern of a natural wood board created and used in the method for manufacturing an embossed decorative material according to the present invention and a conduit border pattern surrounding the conduit pattern.
As shown in FIG. 3A, an original image of a conduit pattern extracted from a wood grain pattern as shown in FIG. 1 is input as an electrical signal by a scanner such as CEPS (COLOR ELECTRONIC PREPRESS SYSTEM) and AD-converted. The digital data of the binarized conduit pattern image P-1 is stored in a storage device such as a hard disk, and the diagram is created in accordance with a specific correction program incorporated so that the border pattern can be trimmed. Digital data of the binarized conduit border pattern image P-2 as shown in 3 (b) is also stored in a storage device such as a hard disk.
[0009]
FIG. 4 is an explanatory diagram of an embossing plate processing step of the embossing decorative material manufacturing method according to the present invention.
First, as shown by (1), the above-mentioned conduit border pattern image P-2 is output (exposed) with a laser beam such as argon ions on the surface of the embossing cylinder 3 coated with the resist sensitizing solution 4 and developed. The resist portion (resist layer) 5 is formed so that only the conduit border pattern image P-2 is a non-resist portion. For this purpose, when a negative resist sensitizing solution is used, only the portion of the conduit border pattern image P-2 is not exposed and the other portions are exposed. In the case of using a positive resist sensitizing solution, only the portion of the conduit border pattern image P-2 is exposed. Then, the non-resist portion is subjected to primary corrosion using a ferric chloride solution or the like to form the conduit edge recess 6 as shown in (2), and the resist is peeled off. One photo-etching process is terminated.
Next, as shown in (3), again, the resist photosensitive solution 4 is applied to the entire surface, and this time, the conduit pattern image P-1 is registered with the conduit border recess 6 and output with laser light (exposure). ) And baking, developing, and providing the resist portion 5 only inside the conduit edging recess portion 6 as shown in (4), and performing secondary corrosion so as to reach a predetermined depth in this state, As shown in {circle over (5)}, the conduit convex portion 7 is formed, the resist is peeled off, the second photoetching step is completed, and the target embossed plate E is obtained.
Further, although not shown in the drawing, a fine uneven shape is formed on the surface of the embossed plate E for controlling the gloss of the decorative material by a method such as sand blasting, and is finished by chromium plating.
[0010]
FIG. 5 is an explanatory diagram of an embossing process of the method for manufacturing an embossed decorative material according to the present invention.
The embossing process which comprises this invention is a process of shape | molding the uneven | corrugated shape formed in the embossing plate E as shown to Fig.5 (a) (6) to the transparent sheet base material 8 heat-softened. The embossed decorative material 10 shown in FIG. 5 (a) (7) is embossed with the uneven shape of the embossed plate E. As a result, a conduit border convex portion is formed around the conduit portion 1. 2 is formed so as to surround the conduit portion 1.
Further, the back surface of the transparent sheet substrate 8 is laminated with a colored sheet substrate 9. The colored sheet base material 9 is preliminarily printed with a wood grain pattern, and the ink layer is not shown, but is sandwiched between the transparent sheet base material 8 and the colored sheet base material 9 or on the surface of the transparent sheet base material 8 Exposed.
A transparent sheet substrate may be used instead of the colored sheet substrate 9.
In the embossing according to the present invention, as shown in FIG. 5 (b), an embossing plate E that functions as a cooling roller with a transparent molten resin extruded from the extruder Ex at a high temperature and the colored sheet substrate 9 is used. A method of pressing between the nip roller (impression cylinder) N, laminating and forming with the embossed plate E and releasing from the embossed plate E through the guide roller G may be adopted.
Alternatively, the heated embossed plate may be pressure-bonded to the transparent sheet base material for shaping, and laminating with the colored sheet base material 9 may be performed off-line.
Moreover, as shown in FIG.5 (c), the ultraviolet-ray or electron beam curable resin liquid m is supplied from the resin liquid supply apparatus M so that at least the recessed part of the embossing plate E surface may be filled, it apply | coats as needed. A transparent topsheet substrate 8 is laminated on the resin liquid M, and the ultraviolet or electron beam curable resin liquid is cured from the embossed plate through the transparent topsheet substrate 8 by using an ultraviolet or electron beam irradiation device D. Although not shown, the colored sheet base material 9 may be laminated off-line.
[0011]
The conduit portion 1 of the laminated material processed as described above is filled with a coloring material C such as dark brown ink such as black-brown by wiping in a separate process, and an operation of bringing the conduit pattern closer to the real thing is performed.
Finally, a backing material corresponding to the purpose of use of the embossed decorative material is lined against the embossed decorative material 10 shown in FIG.
For example, when the embossed decorative material 10 is a door, a honeycomb board or the like is lined using strong bonding to obtain a final product.
[0012]
In the conventional case, generally, the depth of the conduit groove (conduit portion) 1 to be embossed is required to be 100 μm or more, and the thickness D2 of the base material 8 ′ to be formed for this purpose must be 100 μm or more. On the other hand, in the present invention, the depth of the conduit groove 1 to be embossed should be at least 70 μm, and the thickness D1 of the transparent sheet substrate 8 to be used may be at least 70 μm and about 70%. Nevertheless, a cosmetic material 10 that is in no way inferior to the design effect of embossing the conduit pattern is obtained.
This is because by forming the conduit fringing convex portion 2 having a height d around the conduit portion 1, a depth that is the same as the depth of the conventional conduit portion 1 can be secured.
Although it depends on the conduit pattern, generally, the height d of the conduit rim convex portion 2 is desirably in the range of 10 to 30 μm. This is because the design effect is lost when the thickness is 10 μm or less, and when the thickness exceeds 30 μm, abnormalities are felt on the outermost surface. The width of the conduit fringing convex portion 2 is desirably in the range of 50 to 120 μm.
As shown in FIG. 5A, the cross-sectional shape of the conduit rim convex portion 2 is preferably a smooth shape with rounded corners. In particular, increasing the curvature of the inner corner of the conduit groove and decreasing the curvature of the outer corner of the conduit groove does not make the conduit groove uncomfortable compared to natural products, and the depth of the conduit groove. Can be emphasized sufficiently.
The height of the conduit rim convex portion 2 can be controlled by the depth of the conduit rim concave portion 6 obtained by the first corrosion process shown in FIGS. 4 (1) and (2). That is, assuming that the border width of the conduit border pattern image P-2 is 20 to 30 μm, the depth of the conduit border recess 6 caused by the primary corrosion of the non-resist portion obtained by baking the pattern image P-2 is set as follows. If processed into a range of 50 to 100 μm, the depth of the conduit edge recess 6 obtained after the secondary corrosion shown in FIG. Smooth. Since this depth is faithfully formed in the transparent sheet base material 8, the height d of the conduit fringing convex portion 2 is similarly 10 to 30 μm.
In addition, if the use of the transparent sheet base material 8 having the same thickness as that of the conventional one is permitted, the conduit portion 1 having a depth greater than that of the conventional one can be formed, and a deeper and richer textured conduit pattern can be reproduced. It becomes possible.
Further, even when the conduit portion 1 is not filled with the coloring material C, the same visual effect is produced by the shadow that is formed by the light incident on the conduit portion 1 being blocked by the side wall.
As described above, according to the method for producing an embossed decorative material according to the present invention, the uneven pattern such as the grain pattern of natural wood is realistically, powerfully and three-dimensionally despite the transparent sheet substrate 8 having a small thickness. It can be reproduced with a texture.
[0013]
【The invention's effect】
According to the present invention, by providing a contour line composed of the conduit fringing convex portion 2 on the periphery of the conduit portion 1, processing is performed without degrading the visual effect of the conduit emboss even when a thin transparent base material is used. In addition to saving the transparent resin, it is possible to improve the extrusion efficiency of the transparent resin or the film forming efficiency, thereby increasing the production efficiency.
[Brief description of the drawings]
FIG. 1 shows an example of a pattern in which only a conduit pattern formed by a conduit groove is extracted from a grain pattern found in natural wood. FIG. 2 shows an embossed makeup manufactured by the method for manufacturing an embossed decorative material according to the present invention and the prior art. FIG. 3 is a plan view of a conduit pattern of a natural wood board made and used in the embossed decorative material manufacturing method according to the present invention and a conduit border pattern surrounding the conduit pattern. 4 is an explanatory view of an embossing plate processing step of the embossing cosmetic material manufacturing method according to the present invention. FIG. 5 is an explanatory diagram of an embossing processing step of the embossing cosmetic material manufacturing method according to the present invention.
DESCRIPTION OF SYMBOLS 1 Conduit part, Conduit groove 2 Conduit rim convex part 3 Emboss cylinder 4 Resist part, resist layer 5 Non-resist part 6 Conduit rim concave part 6
7 Convex convex portion C Colorant Ex Extruder G Guide roller N Nip roller m Ultraviolet or electron beam curable resin liquid M Ultraviolet or electron beam curable resin liquid supply device P-1 Binary conduit pattern image P- 2 Binarized conduit border pattern image

Claims (4)

Creating digital image data of a conduit pattern of a natural wood board and a conduit border pattern surrounding the conduit pattern;
The digital image data of the conduit border pattern is output (exposed) with a laser beam to the embossed cylinder surface coated with the resist sensitizing solution, and developed to make only the conduit border pattern portion a non-resist portion. Corrosion is performed, resist stripping is performed, and a first photo-etching process for forming a conduit border recess is applied, and a resist photosensitive solution is applied to the cylinder surface on which the conduit border recess is formed, and the guide is aligned with the conduit border recess. Then, the digital image data of the conduit pattern is output (exposed) with a laser beam, developed, and only the conduit pattern portion formed inside the conduit border recess is used as a resist portion. Embossing comprising: a second photoetching step for performing a resist stripping and forming a conduit convex portion having a conduit border recess in the periphery And Linder processing step,
A transparent topsheet base material is hot-pressed by the embossing cylinder, or an ultraviolet ray or an electron beam curable resin liquid is applied and filled on the embossing cylinder surface, and a transparent topsheet base material is laminated as necessary. After the ultraviolet ray or electron beam curable resin solution is cured by ultraviolet ray or electron beam irradiation through the base material, it is released from the embossed plate, thereby forming a conduit groove whose periphery is surrounded by a conduit border convex portion on the transparent base material. Embossing process to
The manufacturing method of the embossing cosmetic material characterized by comprising. 2. The method for producing an embossed cosmetic material according to claim 1 , wherein a colored sheet base material that is grain-printed in-line or offline with the embossing step is laminated on the back surface of the transparent top sheet base material. .   3. The method for producing an embossed decorative material according to claim 1, wherein the conduit is filled with a coloring material.   The manufacturing method of the embossing cosmetic material in any one of Claims 1 thru | or 3 by which the backing material according to a use is affixed on the back surface of the said colored sheet base material.

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